I have never posted so this will be interesting... I have a 1998.5 Ram 2500 HD with the NV4500HD trans and NV241DHD t-case. At 65k I lost 5th gear. Put new gear and nut on and all went well till about 150k when it got hard shifting into 3rd. I had been changing trans and t-case oil every 40k so I pulled the side cover to check what was going on. The trans was nearly dry. I checked the t-case and it had nearly 1 gal. extra fluid in it, so that is wgere the trans oil went. Changed them both and from checking found the trans was pumping its oil into the t-case at the rate of one qt per 1000 mi. It would never come back to the trans. Now at 65k the trans got real loud, found many teeth in bottom of case and the t-case has no input bearing. Before I spend 4k on rebuilt stuff does any one have any idea why the trans sends its fluid to the t-case and never gets it back. I would like to fix the real problem before I cook andther trans and t-case. Thankyou for any help...

Ray Rieli

 

i've never heard of the trans pumping fluid to the tcase. they should have seperate fluid (trans having the synthetic stuff and the tcase haveing ATF) but thats what i remember, but its been 10 years sence i've had a 4x4

 

Maybe the seal between the tranny and t-case is bad or missing....

Rick

 

This is also my first thought.

 

Thank you for your thoughts. Since the t-case input brg is gone I have no way of telling what the condition of the seals were before it took out the bearing. However since the trany pushed its fluid into the t-case but the t-case held it and did not allow the fluid to go back into the trans I would assume the seals were working fairly good. Since the seals cannot hold much pressure I am assuming either the trans was building up pressure and forcing the trans fluid past the seals into the t-case or the vacuum switch on the t-case malfunctioned and sucked the trans fluid past the seals into the t-case. In either case I am replacing the trans breather and the t-case vacuum switch. I am thinking og drilling a vent hole in the dead space between the trans output and the t-case input so pressure from one box cannot go to the other box. What do you think?

Ray

 

Did you replace the nut and gear, or did a shop do it? If a shop, I have a suspicion that they filled the t-case with the tranny fluid instead of the tranny itself.

 

here a though ran into this today, check the vent on the trans, if its clogged it will build pressure inside and push seals out found that on a eaton axle today